Method of Making a High Efficiency Electrical Wire

ABSTRACT

In a method of treating a material solvent, brass granules, copper granules, and carbon nanotubes are mixed, in the absence of silver, iron pyrite, and graphene, to form a first mixture. The first mixture is then added to a second mixture of brass and copper granules. The first and second mixtures are mixed until all of the granules of the second mixture of brass and copper are uniformly saturated with the first mixture, whereafter the second mixture is dried to form a treated material. The treated material can be mixed with one or more metals in a high-temperature crucible and heated until melted to form a metal alloy. Each of the one or more metals can be a ferrous and/or nonferrous metal. The melted metal alloy can be poured into a mold and allowed to cool and harden. The cooled and hardened metal alloy can be formed into a finished form via drawing through a die; continuous casting; or rolling.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the national phase of International application no.PCT/US2016/036413, filed Jun. 8, 2016, which claims the benefit of U.S.provisional application No. 62/172,606, filed Jun. 8, 2015.International application no. PCT/US2016/036413 is also acontinuation-in-part of co-pending U.S. application Ser. No. 15/069,172,filed Mar. 14, 2016, which is a continuation-in-part of co-pending U.S.application Ser. No. 13/771,062, tiled Feb. 19, 2013, (now U.S. Pat. No.9,285,192) which is a continuation of U.S. application Ser. No.12/830,798, filed Jul. 6, 2010 (now U.S. Pat. No. 8,375,840), which is acontinuation-in-part of U.S. application Ser. No. 12/613,902, filed Nov.6, 2009, now abandoned. All of the foregoing referenced applications areincorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

This application relates generally to electrically conductive wire. Morespecifically, this application relates to wire fabricated from a newmetallic mixture employing carbon nanotubes.

Description of Related Art

Electrical wire is a basic, integral part of modern electricalinfrastructure. Electrical wire brings electricity to homes and placesof business and within those units, connects a myriad of electricalappliances to produce all the functions of modern life.

Electrical wiring varies by composition, width and other parameters andis selected based on the desired use, the amount of current to bedelivered, etc.

To date, copper has been the chosen conductor, although other metalsincluding but not limited to aluminum, silver, and gold also areexcellent conductors. Highly purified copper has been the bestconductor. However, adding 200-400 ppm of oxygen has been known toimprove copper conductivity because the oxygen combines with impuritiesto form oxides, which are precipitates from the rest of the copper. Ifthe impurities are not precipitated, they interfere with the copperconductivity.

SUMMARY OF THE INVENTION

Various preferred and non-limiting examples or aspects of the presentinvention will now be described and set forth in the following numberedclauses:

Clause 1: A method of treating a material can comprise: (a) adding asolvent to a high-speed blender; (b) concurrent with or following step(a), adding brass granules to the blender and blending at high speeduntil mixed; (c) concurrent with or following step (a), adding coppergranules to the blender and blending at high speed until mixed; (d)concurrent with or following step (a), adding carbon nanotubes (CNT) tothe blender and blending until mixed; (e) mixing a solution produced bysteps (b)-(d), which solution excludes silver, iron pyrite, andgraphene, into an additional mixture of brass and copper granules andmixing until all of the additional mixture of brass and copper granulesare uniformly saturated with the solution; and (f) drying the mixture ofstep (e) to a dry powder thereby forming a treated material.

Clause 2: The method of clause 1 can further include (g) mixing thetreated material with one or more metals in a high-temperature crucibleand heating until melted thereby forming a metal alloy, wherein each ofthe one or more metals is a ferrous and/or nonferrous metal.

Clause 3: The method of clause 1 or 2 can further include (h) pouringthe melted metal alloy of step (g) into a mold and allowing the pouredmelted metal alloy to cool and harden.

Clause 4: The method of any of clauses 1-3 can further include (i)forming the cooled and hardened metal alloy into a finished form via oneof the following processes: drawing through a die; or continuouscasting; or rolling.

Clause 5: The method of any of clauses 1-4, wherein at least one of thebrass and copper granules can be passed through 100 mesh.

Clause 6: The method of any of clauses 1-5, wherein the solvent can beacetone.

Clause 7: The method of any of clauses 1-6, wherein, in steps (a) and(b), 1.9 liters-3.79 liters (½ gallon-1 gallon) of acetone and 0.45kilograms-0.91 kilograms (1 pound-2 pounds) of brass granules can beadded to the blender.

Clause 8: The method of any of clauses 1-7, wherein, in step (c), 0.45kilograms-0.91 kilograms (1 pound-2 pounds) of copper granules can beadded to the blender.

Clause 9: The method of any of clauses 1-8, wherein each instance ofblending can be repeated for five minute periods.

Clause 10: The method of any of clauses 1-9, wherein, in step (d), 1-2grams of carbon nanotubes (CNT) can be added to the acetone-brass-coppermixture.

Clause 11: The method of any of clauses 1-10, wherein one or the one ormore metals can be copper or aluminum.

Clause 12: The method of any of clauses 1-11, wherein in step (e) themixture of brass and copper can be a 1:1 ratio of brass and copper.

Clause 13: The method of any of clauses 1-12, wherein the mixture ofbrass and copper can comprise 9.1 kilograms-13.6 kilograms (20 pounds-30pounds) of each.

Clause 14: The method of any of clauses 1-13, wherein 3.6 kilograms-9.1kilograms (8 pounds-20 pounds) of the treated material can be added to41 kilograms-54.4 kilograms (90pounds-120 pounds) of the one or moremetals.

Clause 15: The method of any of clauses 1-14, wherein 5 kilograms-5.9kilograms (11 pounds-13 pounds) of treated material can be added to 41kilograms-54.4 kilograms (90pounds-120 pounds) of the one or moremetals.

Clause 16: The method of any of clauses 1-15, wherein steps (b)-(d) canbe performed in any order to produce the solution.

Clause 17: The method of any of clauses 1-16, wherein any two or more ofsteps (a)-(d) can be combined to produce the solution. P Clause 18: Amethod of treating a material can comprise: (a) mixing solvent, brassgranules, copper granules, and carbon nanotubes in the absence ofsilver, iron pyrite, and graphene; (b) adding the mixture of step (a) toan additional mixture of brass and copper granules and mixing until allof the granules of the additional mixture of brass and copper areuniformly saturated with the mixture of step (a); and (c) drying themixture of step (b) to a powder to form a treated material.

Clause 19: The method of clause 18 can further include mixing thetreated material with one or more ferrous and/or nonferrous metal(s) ina high temperature crucible and heating until melted.

Clause 20: The method of clause 18 or 19, wherein step (a) can includemixing in a blender.

Clause 21: A method of treating a material includes mixing solvent,brass granules, copper granules, and carbon nanotubes, in the absence ofsilver, iron pyrite, and graphene, to form a first mixture. The firstmixture is then added to a second mixture of brass and copper granules.The first and second mixtures are mixed until all of the granules of thesecond mixture of brass and copper are uniformly saturated with thefirst mixture, whereafter the second mixture is dried to form a treatedmaterial.

Clause 22: The method of clause 21, wherein the treated material can bemixed with one or more metals in a high-temperature crucible and heateduntil melted to form a metal alloy. Each of the one or more metals canbe a ferrous and/or nonferrous metal.

Clause 23: The method of clause 21 or 22 can further include pouring themelted metal alloy into a mold and allowing the poured melted metalalloy to cool and harden.

Clause 24: The method of any of clauses 21-23 can further includeforming the cooled and hardened metal alloy into a finished form via oneof the following processes: drawing through a die; or continuouscasting; or rolling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating a process for making an exampletreating wash.

FIGS. 2A and 2B are diagrams illustrating front and top views of aballistic strike plate assembly according to another aspect of thepresent invention.

FIGS. 3A and 3B are diagrams illustrating a ballistic strike plateassembly according to another aspect of the present invention.

FIGS. 4A and 4B are diagrams illustrating a ballistic strike plateassembly according to another aspect of the present invention.

FIG. 5 is a schematic of the heat sink with a high-wattage LED lightsource which is also an exemplary heat source;

FIGS. 6A and 6B are perspective views (6B in partial cross-section) ofone example heat sink;

FIGS. 7A and 7B are perspective views (7B in partial cross-section) ofthe example heat sink shown in FIGS. 6A and 6B;

FIGS. 8A, 8B and 8C are schematics illustrating heat transfer from theLED back plate to the heat sink by surface mounting (FIG. 8A), pocketmounting (FIG. 8B) and encasement mounting (FIG. 8C);

FIG. 9 is a perspective view of another example heat sink with numerousseparated pins to dissipate heat;

FIGS. 10A and 10B are perspective views of another example heat sink;FIG. 10A is a perspective view of the heat sink with the heat sourceembedded in a circular area. FIG. 10B is a cross-sectional perspectiveview of the heat sink with the heat source shown at the bottom withmultiple tins to dissipate heat;

FIGS. 11A, 11B and 11C show top, side, and cross-sectional views ofanother exemplary heat sink; and

FIGS. 12 and 13 are diagrams illustrating processes for making exampletreated materials, each of which can be mixed with any ferrous and/ornonferrous metal or combinations of ferrous and/or nonferrous metals(alloys) on the periodic table of the elements to form a metal or alloyhaving improved properties, especially improved electrical and thermalconductance and hardness.

DESCRIPTION OF THE INVENTION

Various nonlimiting examples will now be described with reference to theaccompanying figures where like reference numbers correspond to like orfunctionally equivalent elements.

Persons of ordinary skill in the art will realize that the followingdescription of the present invention is illustrative only and not in anyway limiting. Other embodiments of the invention will readily suggestthemselves to such skilled persons.

The present invention relates to solid-material compositions havingenhanced physical and electrical properties as well as products formedusing the material and methods for making the material and the products.

Numerous products can be made using the composition of the presentinvention. One aspect of the present invention includes a wash or bathemployed to treat ingredients used to form the ballistic strike platesand assemblies according to the present invention. Since the volume ofthe wash or bath will vary with the particular application, anillustrative example is given for formulating the wash using one gallonof acetone. Persons skilled in the art will appreciate that the amountsof the ingredients disclosed in the example can be linearly scaled toformulate larger or smaller batches of the wash.

In one illustrative example shown in FIG. 1, at reference numeral 10,brass is mixed with acetone in a commercial blender. In the example,about 454 grams of brass (about 100 mesh or finer) is mixed with onegallon of acetone in a commercial blender at high speed for about 10minutes or until a gold color appears at the suffice of the acetone whenthe blender is stopped. At reference numeral 12, about 2 grams of silvergranules are added and mixed. At reference numeral 14, carbon nanotubematerial is added and mixed. In the illustrative example, about one gramof multi-walled carbon nanotube material is added and mixed at highspeed for about 5 minutes. At reference numeral 16, iron pyrite is addedand mixed. In the illustrative example, about 33.5 grams of iron pyritehaving a grain size of about 0.125 inch is added and mixed for a minimumof about 3 minutes at high speed. At reference numeral 18, copper isadded and mixed. In the illustrative example, about 517 grains of copper(about 100 mesh or finer) is added and mixed at high speed for about 8minutes until a slurry begins to form on the surface after the blenderis turned off. The order in which the carbon nanotube material, thesilver, the iron pyrite, and the copper are added is not critical.

After the ingredients have all been mixed as described, the liquid isstrained and may be used as a wash or bath. All of the strained solidmatter (herein “the first example treated material”) may be stored forfurther use as disclosed herein. Once materials are processed, the washliquid used may be collected and recycled by adding it to new batches ofthe wash liquid.

Once the wash liquid is formulated, constituent materials of products tobe fabricated are washed using it. A sticky film merges with theconstituent materials. The constituent materials are bonded together bydrying and application of pressure, either in an oven or at roomtemperature.

According to one aspect of the present invention, ballistic strikeplates formed from a special aluminum alloy are advantageously employedin armor assemblies, especially body armor assemblies. Since the amountof alloy needed to form plates of particular dimensions will vary withsizes of the plates needed for the particular application, anillustrative example is given for formulating a kilogram of the alloy.Persons skilled in the art will appreciate that the amounts of theingredients disclosed in the example can be linearly scaled to formulatelarger or smaller amounts of the aluminum alloy.

For a total weight of about 1 Kg of special aluminum alloy, about 130grams of the first example treated material as described above and about10 grams of silver powder are melted into about 860 grams of aluminum.The aluminum alloy formulated according to the present invention as justdescribed is referred to herein as “special aluminum alloy.”

The ballistic strike plates of the present invention may be formed byhot rolling ingots of the special aluminum alloy or may be formed bycasting from the molten alloy. The ballistic strike plates of thepresent invention may be formed by hot rolling ingots of aluminum orother aluminum alloys or may be formed by casting from molten aluminumor other aluminum alloys but are believed to have a lower strength thanthe special aluminum alloy. Thickness of the finished ballistic strikeplates will vary according to the particular application; for body armorthe plates may be about 0.0625 inch to about 0.250 inch thick, dependingon the threat level they are designed to meet. For vehicle or structurearmor the ballistic strike plates may have a thickness of up to an inchor greater, depending on the threat level they are designed to meet.

Referring now to FIGS. 2A and 2B, the composition is usefully employedto form a ballistic strike plate 20 that may be used in body armoraccording to another aspect of the present invention. FIG. 2A shows afront view of a ballistic strike plate assembly according to the presentinvention. FIG. 2B shows an illustrative top view of strike plateassembly 20. While the illustrative bottom view shown in FIG. 2Aindicates that plate 20 is curved, persons of ordinary skill in the artwill appreciate that plate 90 may be formed flat, depending on theapplication. For example, body-armor vests are sometimes constructed bysupplying a vest made from a fabric material. The vests contain pocketsinto which ballistic strike plates or plate assemblies are inserted. Theballistic strike plate assemblies according to the present inventioninclude assemblies formed in this manner and configured to be insertedinto the pockets of such fabric vests.

Referring now to FIGS. 3A and 3B, diagrams illustrate a cross-sectionalview and a face view, respectively, of a ballistic strike plate assembly30 according to another aspect of the present invention.

An illustrative ballistic plate assembly according to the presentinvention is formed using a special aluminum alloy plate 32 madeaccording to the present invention. In one illustrative embodiment ofthe invention, plate 32 may have a thickness of about 0.125 inches. Agrade II titanium plate 34 such as a 0.125 inch thick plate CAS7440-32-6 available from Allegheny Ludlum Corp., of Brackenridge, Pa. isalso used. While in the present example the two plates have the samethickness, this is not necessary for practicing the present invention.Persons of ordinary skill in the art will recognize that the thicknessesof plates 32 and 34 will be selected according to the threat level towhich the ballistic strike plate assembly will be designed to encounter.

A sheet of ballistic gap foam 36, having a thickness of about 0.125inches in an illustrative embodiment, having adhesive disposed on bothsurfaces, such as model DMG-FM-004, manufactured by DMG, a division ofHisco, of Tempe Ariz., is adhered to a first surface of one of theplates. A first surface of the other plate is adhered to the othersurface of the foam sheet 36.

A ballistic fabric plate 38 is made using multiple layers of a ballisticfabric such as Spectra II available from Honeywell of Colonial Heights,Va. in a presently preferred embodiment, a first stack of a plurality oflayers of such fabric. A sheet 40, formed from a material such as atitanium sheet, having a thickness of about 0.05 inches in anillustrative embodiment, such as a CAS 7440-32-6 plate from AlleghenyLudlum Corp. of Brackenridge, Pa., is placed over the stack and a secondstack of a plurality of layers of such fabric are placed over thetitanium sheet. In one illustrative embodiment of the invention, fiftysheets are employed in the first and second stacks. The assembled stacksare then heated to about 275. degree. F. for about four hours under apressure of, for example, 10 tons to form a ballistic fabric plate. Theballistic fabric plate is adhered to the exposed second surface of thealuminum plate 32 using a double-sided adhesive tape 42, such as 3M-VHB4950, available from 3M Corporation of St. Paul, Minn.

The ballistic plate assembly 30 is then covered with a first sheet 44 ofballistic wrap such as M-7 Spall System Nylon PSA from DMG a division ofHisco of Tempe Ariz. The first sheet 44 of ballistic wrap is held inplace by a layer of adhesive 46. The edges 48 of the first sheet ofballistic wrap 44 are folded over the four edges of the assembly. Asecond smaller sheet of ballistic wrap 50 is placed over the portion ofthe second surface of the aluminum plate not covered by the folded overedges of the first sheet of ballistic wrap. The second sheet 50 ofballistic wrap is also held in place by a layer of adhesive 46. Thetitanium face of the assembly faces outward towards the threat.

Referring now to FIGS. 4A and 4B, diagrams illustrate a cross-sectionalview and a face view, respectively, of a body-armor plate assemblyaccording to another aspect of the present invention.

According to the aspect of the present invention illustrated in FIGS. 4Aand 4B, an armor plate assembly 60 is formed using a special aluminumalloy plate 62 made according to the teachings of the present invention.In one illustrative embodiment of the invention, plate 22 may have athickness of about 0.125 inches. A grade II titanium plate 64 such as a0.125 inch thick plate CAS 7440-32-6 available from Allegheny LudlumCorp., of Brackenridge, Pa. While in the present example the two plateshave the same thickness, this is not necessary for practicing thepresent invention. Persons of ordinary skill in the art will recognizethat the thicknesses of plates 62 and 64 will be selected according tothe threat level to which the ballistic strike plate assembly will bedesigned to encounter.

A first surface of a sheet of ballistic gap foam 66, having a thicknessof about 0.125 inches in an illustrative embodiment, having adhesivedisposed on both faces, such as model DMG-FM-004, manufactured by DMG, adivision of HISCO, of Tempe Ariz., is adhered to a first surface of oneof the plates 62 and 64. A first surface of the other plate is adheredto the other surface of the foam sheet 66.

A ballistic backing plate 68 is made using multiple layers of aballistic fabric such as Spectra II available from Honeywell of ColonialHeights, Va. In a presently preferred embodiment, a stack is assembledfrom a plurality of layers of such fabric. A sheet 70 formed from amaterial such as a titanium sheet, having a thickness of about 0.05inches in an illustrative embodiment, such as a CAS 7440-32-6 plate fromAllegheny Ludlum Corp. of Brackenridge, Pa. is placed over the stack anda second stack of a plurality of layers of such fabric are placed overthe titanium sheet. In one illustrative embodiment of the invention,fifty sheets are employed in the first and second stacks. The assembledstacks are then heated to about 275.degree. F. for about four hoursunder a pressure of, for example, 10 tons to form ballistic fabric plate68. The ballistic fabric plate 68 is adhered to the exposed secondsurface of the aluminum plate 62 using a double sided adhesive tape,such as 3M-VHB 4950, available from 3M Corporation of St. Paul, Minn.

The ballistic plate assembly 60 is then covered with a first sheet 74 ofballistic wrap such as M-7 Spall System Nylon PSA from DMG a division ofHisco of Tempe Ariz. The first sheet 74 of ballistic wrap is held inplace by a layer of adhesive 76. The edges 78 of the first sheet ofballistic wrap 74 are folded over the four edges of the assembly. Asecond smaller sheet of ballistic wrap 80 is placed over the portion ofthe second surface of the aluminum plate not covered by the folded overedges of the first sheet of ballistic wrap. The second sheet 80 ofballistic wrap is also held in place by a layer of adhesive 76. Thetitanium face of the assembly faces outward towards the threat.

A coating 82, for example an elastomeric coating such as Plasti-Dipcoating from Plasti-Dip International of Blaine, Minn., is formed overthe seams 84 made by the intersection of the edges of folded-overportions 78 of the first sheet of ballistic wrap layer 74 and at theouter edges 86 of the second sheet 80 of the ballistic wrap.

In another example, a second example treated material is disclosedhereafter that can be mixed with any ferrous or nonferrous metal orcombination of two or more ferrous and/or nonferrous metals on theperiodic table of the elements to form a metal or metal alloy havingimproved properties, especially improved electrical and thermalconductance and hardness. An example target application for this newmetal or alloy is a heat sink for a 255 Watt LED light source thatoutputs 25,000 lumens of light without using fans. Requirements for thisLED light source included operation temperatures less than 85° C. forprolonged intervals of time (e.g., overnight) without causing thermaldamage to the LED light source. Another requirement was no moving partsor mechanisms requiring external supervision or maintenance, becausefailure to such moving parts would cause failure of the LED lightsource. The LED light source by itself should also be able to stayoperational for over 20 years without maintenance.

Turning to FIG. 5, an example heat sink 1 is illustrated. Generally,heat sinks are passive heat exchangers that cool an attached or adjacentheat source, such as an LED light source by dissipating heat into thesurrounding medium. In general, the performance of a heat sink isaffected by the material(s) and properties of the materials forming theheat sink, the mass of the material, and the surface area available forheat exchange with a cooler medium than the heat source. In an example,a heat sink for an LED light source can optionally be accompanied by afan for faster dispersion of heat therefrom.

The example heat sink 1 includes a base plate 7 that abuts the LED lightsource 2 (i.e., a single LED or multiple LEDs). LED light source 2 canhave a base plate 6 to provide a surface for heat transfer to heat sinkbase plate 7. Thermal paste or other greases 5 can be optionally used toimprove heat transfer between abutting surfaces of base plates 6 and 7.Base plate 7 can have various shaped fins extending from base plate 7that serve to provide surface area for heat exchange to ambient air 3surrounding heat sink 1. Heating of air 9 adjacent fins 8 of heat sink 1induces a natural conduction generating air flow cooling heat sink.Operation of the heat sinks 1, 101 (FIGS. 6A-7A) requires airflow 3, 9.

Designs for heat sink 1 are presented in FIGS. 6A-11C. In an example,the design of heat sink 101 is governed by the same principles used forheat sink 1. It is believed that when used to make parts of a heat sink,such as fins 8, the new metal or alloy formed using the second exampletreated material (discussed hereinafter) can improve the efficiency ofheat exchange, allowing the heat sink to handle cooling of higherheat-generating sources, such as LED light source 2. In an example, themass of a base plate 107 of heat sink 101 is selected to handle thewattage of LED light source 2. However, this mass is less than whatwould be required by heat sinks made from the prior art metals oralloys.

In an example, the shape of the base plate 107 shown in FIGS. 6A-79 wasmade collinearly bell shape (shown best in FIG. 7B) to focus the massdirectly behind the LED light source 2 to absorb heat efficiently.However, any shape can be used for base plate 107 made from the newmetal or alloy. In an example, the thermal mass of base plate 107 muststill stay below a given saturated equilibrium, where it can no longerabsorb additional heat from the LED light source 2. Fins 108 made fromthe new metal or alloy stay cooler and are more effective exchangingheat with air than fins 108 made from prior art metals or alloys. In anexample, fins 108 can be modularly attached to the base plate 107 toallow for ease of trying different fin designs. Optionally, fins 108 canbe directly cast with base plate 107. Heat sink 101 can optionallyinclude an upper attachment 111 and/or a lower attachment 112 toassemble fins 108 to base plate 107 and to provide additional coolingsurface area. Heat source 101 can include additional structures (notshown), such as a focusing lens for LED light source 2 and/or structuralmounting components for supporting heat sink 101 for use.

In developing heat sink 101, fundamental relationships used fordesigning heat sinks were questioned with increasing surface area.Variations in heat sink mass appeared to exert a greater effect on theoverall thermal conductivity rate than adjusting the amount of theexposed surface area to the ambient air. While not wishing to be boundby any particular theory, it is believed this is due to the efficacy ofthe conductivity of the new metal or alloy being greater than that ofprior art metallic materials. The new metal or alloy also transfers heatfrom LED light source 2 at a greater rate. Sufficient mass was requiredto stay within the thermal mass limit for the LED light source 2 priorto saturation, where saturation was taken as having insufficient mass,where equilibrium states in temperatures between the LED's base plate 6and adjacent surface material within the heat sink would approachallowing temperatures in the LED to increase above operational limits.

The physical mounting/placement of LED light source 2 and its backingplate 6 with the base plate 7, 107 of heat sink 1, 101 played a role inthe effectiveness of heat transfer as will now be discussed withreference to FIGS. 8A-C. In an example, surface mounting back plate 6 ofLED light source 2 to heat sink 107 of heat sink 101 providessurface-to-surface contact (FIG. 8A). In another example, submergingback plate 6 of LED light source 2 into a pocket P of base plate 107improves heat transfer, particularly with including edges of the baseplate 6 within base plate 107 to wick heat from around a perimeter ofbase plate 6 (FIG. 8B). In another example, encasement of base plate 6on all exposed surfaces with components, e.g., upper attachment 111 andbase plate 107 of heat sink 101, provided the best heat transfer (FIG.8C).

In an example, various materials 6 can be inserted between base plate 6,106 and base plate 7, 107 including, but not limited to, grease,insulating mica washer, thermally conductive tape, epoxy, wire-form Zclips, standoff spacers, push pins with expandable ends, and flat sprigclips. These materials can optimize thermal conductivity between baseplate 6, 106 and base plate 7, 107, which may not have perfectly evensurfaces for maximal heat transfer.

In an example, carbon nanotubes (CNT) and graphene are used to form thenew metal or alloy. It has been observed that the addition of smallamounts of CNT and graphene to a ferrous and/or nonferrous metal, and/ora combination of ferrous and/or nonferrous metals results in higher heatconductivity in the resulting metal or alloy. In an example, twoattempts to measure thermal conductivity of the new metal or alloyformed with CNT and graphene exceeded the heat conductivity measurableon equipment routinely used to measure heat conductivity. CNT (single-or multiple-walled carbon nanotubes) and graphene are available frommany commercial sources.

In an example, the second example treated material (describedhereinafter) can be mixed with one or more of the following to form oneexample of the new metal or alloy: aluminum (new or recycled), copper,tungsten, carbide, silver, steel, lead, and combinations thereof. Thethus formed new metal or alloy can be used in a variety of compositesincluding, for example, beryllium oxide in a beryllium matrix. The newmetal or alloy can also be utilized with diamonds, and/or siliconcarbide in aluminum matrix, for example, a matrix of diamond in acopper-silver matrix, and plastics.

In an example, a variety of fin 8, 108 arrangements were tested,including straight and curved tins that were removably attached, ormolded into the heat sink. In an example, fins are cross-cut at regularintervals to enable more air flow. In an example, the heat sink designdescribed herein must be weighted under the heat source more thantypical designs. Larger lateral projections were not as successful.

An example of a process for forming the second example treated materialwill now be described with reference to FIG. 12. In this example, thesecond example treated material can be used with any ferrous and/ornonferrous metal or combination of metals on the periodic table of theelements, including, without limitation, aluminum (new or recycled),copper, steel, lead, and combinations thereof. The second exampletreated material can also be utilized to treat nonmetallic materials,such as plastic.

In an example, at reference numeral 210 brass is mixed with acetone in acommercial blender. In an example, about 454 grams (1 pound) of brassgranules (in an example, 100 mesh or finer) is mixed with about 1.9liters (0.5 gallons) of acetone in a commercial blender at high speeduntil a gold color appears at the surface of the acetone when theblender is stopped. In an example, the brass granules and acetone weremixed in about five-minute increments until the gold color appeared atthe surface of the acetone. This mixing produces an acetone-brass (AB)combination.

At reference numeral 212, about 454 grams (1 pound) of copper granules(in an example, 100 mesh or finer) are added to the AB combination andmixed for about 5 minutes to ensure complete mixing. This produced anABC combination.

At reference numeral 214, about one gram of carbon nanotube (CNT)material is added to the ABC combination in the blender to form anABC-CNT mixture. This ABC-CNT mixture was mixed for about five minutesproducing an ABC-CNT combination.

Next, at reference numeral 216, one gram of graphene (G) is added to theABC-CNT combination in the blender mixed at high speed for about fiveminutes to form an ABCG-CNT mixture.

At reference numeral 218, the ABCG-CNT combination is mixed with amixture of brass and copper granules (in an example, each of which is100 mesh or finer). In an example, the mixture of brass and coppergranules of step 218 is a 50/50 or 1:1 mixture of brass and coppergranules. In an example, the 50/50 mixture of brass and granulesincludes, for example, about 11.3 kilograms (25 pounds) of brass andabout 11.3 kilograms (25 pounds of copper) to produce an ABCG25-CNTmixture that is mixed for about ten minutes and/or until all thematerials are uniformly saturated.

The order in which the brass, copper, CNT, graphene, and brass/coppermixture are combined or mixed is not crucial. Moreover, two or more ofsteps 210-216 can be combined into a single step if desired.Accordingly, the foregoing example is not to be construed in a limitingsense.

The process of mixing acetone, brass, and copper in steps 210 and 212with a commercial blender has the effect of knocking small particles ofbrass and copper from the brass and copper granules, which smallparticles become suspended in the acetone due to the action of thecommercial blender running at high speed. Once these small particles arein suspension within the acetone, they can readily combine with the CNT,graphene, and mixture of brass and copper granules in steps 214-218.

After all of the ingredients in steps 210-218 have been mixed, theABCG25-CNT combination is fully dried to form an ABCG25-CNT powder thatis free of residual solvent. This ABCG25-CNT powder is the secondexample treated material.

The thus prepared second example treated material can be mixed with anyferrous or nonferrous metal, or combinations of ferrous and/ornonferrous metals of the periodic table of the elements in ahigh-temperature crucible with induction heater for casting metals.Hereinafter, the “ferrous or nonferrous metal” or “combinations offerrous and/or nonferrous metals” will be individually or collectivelyreferred to as “the ferrous and/or nonferrous metal(s)”.

The ferrous and/or nonferrous metal(s) can be the same or different fromthose in the second example treated material.

In an example, the second example treated material can be added at thestart of melting the ferrous and/or nonferrous metal(s) prior tocasting. However, in another example, the second example treatmentmaterial can be added to the ferrous and/or nonferrous metal(s) at anytime.

In an example, a ratio of the second example treated material to theferrous and/or nonferrous metal(s) can be about 5 kilograms-5.9kilograms (11 pounds-13 pounds) of the second example treated materialto 41 kilograms-54.4 kilograms (90 pounds-120 pounds) of the ferrousand/or nonferrous metal(s). In an example, the transition of the ferrousand/or nonferrous metal(s) mixed with the second example treatedmaterial required a higher temperature than normally used for saidferrous and/or nonferrous metal(s) not mixed with the second exampletreated material and was in the range of about 815° C. to 1538° C.(1500° F. to 2800° F.), depending on the ferrous and/or nonferrousmetal(s) used. In an example, degassing means were utilized duringmixing of the second example treated material with the ferrous and/ornonferrous metal(s) to ensure safety.

In the foregoing example, acetone was used as a solvent. However, it isenvisioned that other solvents can be utilized, examples of othersuitable solvents include polar or nonpolar solvents. Examples of polarsolvents include water, acetone, alcohol, dimethylformamide,n-methyl-2-pyrrolidone, dichloroethylene, or chloroform.

The times, weights, and ratios of the weights given above are examplesfor the purpose of illustration only and may be varied by one skilled inthe art to obtain desired results. For example, in each of steps 210 and212 above, anywhere between 0.34 kilograms-0.9 kilograms (0.75 pounds-2pounds) of brass and copper can be added; the solvent can vary fromabout 1.9 liters-7.6 liters (0.5 gallon-2 gallons). CNT can be variedfrom 0.5 grams-10 grams, in an example from 0.6 grams-5 grams, inanother example from 0.8 grams-2 grams. In addition, as discussed above,the order of steps 210-218 can be varied by one skilled in the artand/or steps 210-218 can be combined as necessary for convenience. Forexample, without limitation, the brass and copper granules of steps210-212 may be added to the acetone in the blender at the same time. TheABC25G-CNT powder can be optionally filtered after being dried.

The weights of brass and copper discussed above in connection with step218 were chosen for effectiveness as well as convenience with theavailable equipment and can be varied depending on desired parameters aswell as sizes of mixing containers. The weight of each of brass andcopper in step 218 can range from 6.8 kilograms-22.6 kilograms (15pounds-50 pounds), in another example between about 9.1 kilograms-15.9kilograms (20 pounds-35 pounds), and in another example between about 10kilograms-13.6 kilograms (22 pounds-30 pounds). Similarly, the amount ofthe second example treated material, namely, the ABCG25-CNT powder canbe varied when added to the ferrous and/or nonferrous metal(s).Accordingly, the foregoing examples including weights and/or ratio ofweights and mixing times are not to be construed in a limiting sense butonly as examples of forming the second example treated material andusing the second example treated material to form the treated metal oralloy.

Before or during the melting of the ferrous and/or nonferrous metal(s)in the casting operation, other additives can be added, such as, in anexample, metallic alloys, plastic, cloth, or any combination thereof.

It is believed that using the second example treated material enablesthe material being treated, for example, the ferrous and/or nonferrousmetal(s), to achieve greater electrical and mechanical properties thansaid ferrous and/or nonferrous metal(s) would achieve without the secondexample treated material. It is also believed that one or more of thefollowing properties of ferrous and/or nonferrous metal(s) mixed withthe second example treated material are improved by use of the secondexample treated material in the manner discussed above: thermalconductance, electrical conductance, hardness, and resistance tomicrowaves. In addition, in an example, it is believed that the secondexample treated material and/or the ferrous and/or nonferrous metal(s)treated with the second example treated material can be part of acoating that can be applied in any suitable and/or desirable manner toother materials such as metal, plastic, cloth, etc. to form a coating onsaid other materials.

Another application of the ferrous and/or nonferrous metal(s) treatedwith the second example treated material is electrical wire. In anexample, the ferrous and/or nonferrous metal(s) treated with the secondexample treated material can be used to make electrical wire gradecopper or aluminum.

In another example, a third example treated material is describedhereafter that can be mixed with any ferrous or nonferrous metal orcombination of two or more ferrous and/or nonferrous metals on theperiodic table of the elements to form a metal or metal alloy havingimproved properties, especially improved electrical conductivity. Anexample target application for this new metal or alloy is electricalwire used to conduct electricity.

In an example, the third example treated material (describedhereinafter), can be mixed with one or more of the following to form oneexample of the new metal or alloy: aluminum (new or recycled), copper,tungsten, silver, brass, steel, lead, and combinations thereof. The thusformed new metal or alloy can be used in a variety of composites,including, for example, beryllium oxide in a beryllium matrix. The newmetal or alloy can also be utilized with diamonds, and/or siliconcarbide in an aluminum matrix, for example, a matrix of diamond in acopper-silver matrix, and plastics.

Brass is known to be an alloy of copper and zinc. It is available in awide range of ratios. In an example, brass can have a copper range of50-97% and a zinc range of 3-50%. Brass is known for its low frictionand high workability. In an example it can be strengthened with aluminumto form a highly beneficial hard layer of aluminum oxide. Adding iron,aluminum, silicon, and manganese to brass makes it more durable. Thecopper in brass makes brass germicidal, so microbial damage to the newmetal or alloy formed with e third example treated material describedhereinafter is avoided.

An example process for forming the third example treated material willnow be described with reference to FIG. 13. In this example, the thirdexample treated material can be used with any ferrous and/or nonferrousmetal or combination of metals on the periodic table of the elements,including, without limitation, aluminum (new or recycled), copper,steel, lead, and combinations thereof. The third example treatedmaterial can also or alternatively be utilized to treat non-metallicmaterials, such as plastic. Experience with the third example treatedmaterials suggests that the new metal or alloy formed with the thirdexample treated material can be used with other host metals that are atleast minimally electrically conductive, as well as on some non-metallicmaterials, such as, without limitation, plastics, rubber, fabric, andpaper.

Referring to FIG. 13, in an example, at reference number 310, brass ismixed with acetone in a commercial blender. In an example, about 454grams (1 pound) of brass granules (in an example, 100 mesh or finer) ismixed with about 3.8 liters (1.0 gallons) of acetone in a commercialblender at high speed until a gold color appears at the surface of theacetone when the blender is stopped. In an example, the brass granulesand acetone were mixed in about 5 minute increments until the gold colorappeared at the surface of the acetone. This mixing produced anacetone-brass (AB) combination. At reference number 312, about 454 grams(1 pound) of copper granules (in an example, 100 mesh or finer) areadded to the AB combination and mixed for about 5 minutes to ensurecomplete mixing. This produced an ABC combination.

At reference number 314, about 1 gram of carbon nanotube (CNT) materialis added to the ABC combination in the blender to form an ABC-CNTmixture. This ABC-CNT mixture was mixed for about 5 minutes producing anABC-CNT combination. At reference 316, the ABC-CNT combination is mixedwith a mixture of brass and copper granules (in an example, each ofwhich is 100 mesh or finer). In an example, the mixture of brass andcopper granules of step 316 is a 50/50 or 1:1 mixture of brass andcopper granules. In an example, the 50/50 mixture of brass and granulesincludes, for example, about 11.3 kilograms (25 pounds) of brass andabout 11.3 kilograms (25 pounds) of copper to produce an ABC25-CNTmixture that is mixed for about 10 minutes and/or until all thematerials are uniformly saturated.

In an example, all mixing described herein occurs in a commercialblender. However, this is not to be construed in a limiting sense.

The order in which brass, copper, CNT, and the brass/copper mixture arecombined or mixed is not crucial. Moreover, two more of steps 310-314can be combined into a single step if desired. Accordingly, theforegoing example is not to be construed in a limiting sense.

The process of mixing acetone, brass, and copper in steps 310 and 312with a commercial blender has the effect of knocking small particles ofbrass and copper from the brass and copper granules, which smallparticles become suspended in the acetone due to the action of thecommercial blender running at high speed. Once these small particles arein suspension within the acetone, they can readily combine with the CNT,and the mixture of brass and copper granules in steps 314 and 316. Afterall of the ingredients in steps 310-316 have been mixed, the ABC25-CNTcombination is fully dried to form an ABC25-CNT powder that is free ofresidual solvent. This ABC25-CNT powder is the third example treatedmaterial.

The thus prepared third example treated material can be mixed with anyferrous or nonferrous metal, or combinations of ferrous and/ornonferrous metals of the periodic table of the elements in ahigh-temperature crucible with induction heater for casting metals.Hereinafter, the “ferrous or nonferrous metals” or “combinations offerrous and/or nonferrous metals” will be individually or collectivelyreferred to as “the ferrous and/or nonferrous metal(s)”.

The ferrous and/or nonferrous metal(s) can be the same or different fromthose in the first or second example treated materials described above.

In an example, the third example treated material can be added at thestart of melting the ferrous and/or nonferrous metal(s) prior tocasting. However, in another example the third example treated materialcan be added to the ferrous and/or nonferrous metal(s) at any time.

It is to be appreciated that the third example treated material isprepared without the use of silver and iron pyrite, used to prepare thefirst example treated material, and without graphene used to prepare thethird example treated material. Accordingly, the third example treatedmaterial is distinguishable over the first and second example treatedmaterials by the absence of silver, iron pyrite, and graphene.

In an example, a ratio of the third example treated material to theferrous and/or nonferrous metal(s) can be about 5 kilograms-5.9kilograms (11 pounds-13 pounds) of the third example treated material to41 kilograms-54.4 kilograms (90 pounds-120 pounds) of the ferrous and/ornonferrous metal(s). In an example, the transition of the ferrous and/ornonferrous metal(s) mixed with the third example treated materialrequired a higher temperature than normally used for said ferrous and/ornonferrous metal(s) not mixed with the third example treated materialand was in the range of about 815° C. to 1538° C. (1500° F. to 2800°F.), depending on the ferrous and/or nonferrous metal(s) used. In anexample, degassing means were utilized during mixing of the thirdexample treated material with the ferrous and/or nonferrous metal(s) toensure safety.

After the mixture is completely melted, it was poured into long narrowmolds where it was allowed to cool, after which it was drawn to makenarrow gauge wires. In an example, the drawing process can be done withpolycrystalline dyes or natural single crystal diamond dyes.Alternatively, in an example, instead of a drawing process, the cool,molded mixture can be formed utilizing a continuous casting and rollingprocess. The dust formed narrow gauge wires exhibited a hardness of 85on the Rockwell Scale versus a hardness of 110 for a spherical coppersample.

In an example, various materials can be used to coat the thus formedwires, including, in an example, grease, an insulating mica washer,thermally conductive tape, epoxy, wire-form Z clips, standoff spacers,push pins with expandable ends, and flat spring clips. These devices andmaterials optimize the junction of the wire and connections with otherdevices.

In the foregoing example, acetone was used as a solvent. However, it isenvisioned that other solvents can be utilized, examples of othersuitable solvents include polar or nonpolar solvents. Examples of polarsolvents include water, acetone, alcohol, dimethylformamide,n-methyl-2-pyrrolidone, dichloroethylene, or chloroform.

The times, weights, and ratios of the weights given above are examplesfor the purpose of illustration only and can be varied by one skilled inthe art to obtain desired results. For example, in each of steps 310 and312 above, anywhere between 0.34 kilograms-0.9 kilograms (0.75 pounds-2pounds) of brass and copper can be added; the solvent can vary fromabout 1.9 liters-7.6 liters (0.5 gallons-2 gallons). CNT can be variedfrom 0.5 grams-10 grams, in an example from 0.6 grams-5 grams, inanother example from 0.8 grams-2 grams. In addition, as discussed above,the order of steps 218 to 310-314 can be varied by one skilled in theart and/or steps 310-314 can be combined as necessary for convenience.For example, without limitation, the brass and copper granules of steps310-312 can be added to the acetone in the blender at the same time. TheABC25G-CNT powder can be optionally filtered after being dried.

The weights of brass and copper discussed above in connection with step316 were chosen for effectiveness as well as convenience with theavailable equipment and can be varied depending on desired parameters aswell as sizes of mixing containers. The weight of each of brass andcopper in step 316 can range from 6.8 kilograms-22.6 kilograms (15pounds-50 pounds), in another example between about 9.1 kilograms-15.9kilograms (20 pounds-35 pounds), and in another example between about 10kilograms-13.6 kilograms (22 pounds-30 pounds). Similarly, the amount ofthe third example treated material, namely, the ABC25-CNT powder can bevaried when added to the ferrous and/or nonferrous metal(s).Accordingly, the foregoing examples including weights and/or ratio ofweights and mixing times are not to be construed in a limiting sense butonly as examples of forming the third example treated material and usingthe third example treated material to form the treated metal or alloy.

Before or during the melting of the ferrous and/or nonferrous metal(s)in the casting operation, other additives can be added, such as, in anexample, metallic alloys, plastic, cloth, or any combination thereof.

It is believed that using the third example treated material enables thematerial being treated, for example, the ferrous and/or nonferrousmetal(s), to achieve greater electrical and mechanical properties thansaid ferrous and/or nonferrous metal(s) would achieve without the thirdexample treated material. It is also believed that one or more of thefollowing properties of ferrous and/or nonferrous metal(s) mixed withthe third example treated material are improved by use of the thirdexample treated material in the manner discussed above: thermalconductance, electrical conductance, hardness, and resistance tomicrowaves. In addition, in an example, it is believed that the thirdexample treated material and/or the ferrous and/or nonferrous metal(s)treated with the third example treated material can be part of a coatingthat can be applied in any suitable and/or desirable manner to othermaterials such as metal, plastic, cloth, etc. to form a coating on saidother materials.

In an example, a mixture formed by mixing the third example treatedmaterial with copper (in the ratios discussed above) was molded into asmall cup with a cover. This cup was partially filled with water and alive inchworm was placed therein. The cover was then placed on thefilled cup which was then placed inside of a home-grade microwave nextto a coffee mug filled with water. The microwave was operated for 3minutes on full power. Both the mug and the cup were removed from themicrowave whereupon the water in the mug was observed to be steaming butthe water in the cup formed from the copper mixture was still cool tothe touch and the inchworm was observed to be moving.

In another example, the cup was also used to test the effects on digitalstorage devices (thumb drives) to microwave radiation. In this example,a thumb device partially loaded with files was placed in the cup and thelid placed thereon. After 3 minutes of exposure to microwaves in thehome-grade microwave at full power, the thumb drive was removed from thecup and inserted into a computer port. The files were observed to stillbe readable. This latter example suggests that the copper mixture formedfrom the third example treated material can be used for safecontainment, transport, and storage of materials or elements that emitionizing radiation, such as isotypes used for nuclear medicine, nuclearwaste, and the like. This copper alloy blocks radiation and is anexcellent heat sink, features that will contain radiation but avoid heatbuildup. This copper alloy can replace all or a part of thick steel usedin current containers. Hospital and clinic treatment rooms can benefitfrom containers made with the copper alloy for containment ofadministered isotopes in a variety of tests. Moreover, spent nuclearreactor fuel, which is highly radioactive and often hot, can becontained.

The examples have been described with reference to the accompanyingfigures. Modifications and alterations will occur to others upon readingand understanding the foregoing examples. Accordingly, the foregoingexamples are not to be construed as limiting the disclosure.

The invention claimed is:
 1. A method of treating a material comprising:(a) adding a solvent to a high-speed blender; (b) concurrent with orfollowing step (a), adding brass granules to the blender and blending athigh speed until mixed; (c) concurrent with or following step (a),adding copper granules to the blender and blending at high speed untilmixed; (d) concurrent with or following step (a), adding carbonnanotubes (CNT) to the blender and blending until mixed; (e) mixing asolution produced by steps (b)-(d), which solution excludes silver, ironpyrite, and graphene, into an additional mixture of brass and coppergranules and mixing until all of the additional mixture of brass andcopper granules are uniformly saturated with the solution; and (f)drying the mixture of step (e) to a dry powder thereby forming a treatedmaterial.
 2. The method of claim 1, further including: (g) mixing thetreated material with one or more metals in a high-temperature crucibleand heating until melted thereby forming a metal alloy, wherein each ofthe one or more metals is a ferrous and/or nonferrous metal.
 3. Themethod of claim 2, further including: (h) pouring the melted metal alloyof step (g) into a mold and allowing the poured melted metal alloy tocool and harden.
 4. The method of claim 3, further including: (i)forming the cooled and hardened metal alloy to a finished form via oneof the following processes: drawing through a die; or continuouscasting; or rolling.
 5. The method of claim 1, wherein at least one ofthe brass and copper granules are passed through 100 mesh.
 6. The methodof claim 1, wherein the solvent is acetone.
 7. The method of claim 1,wherein, in steps (a) and (h), 1.9 liters-3.79 liters (½ gallon-1gallon) of acetone and 0.45 kilograms 0.91 kilograms (1 pound-2 pounds)of brass granules are added to the blender.
 8. The method of claim 1,wherein, in step (c), 0.45 kilograms 0.91 kilograms (1 pound-2 pounds)of copper granules are added to the blender.
 9. The method of claim 1,wherein each instance of blending is repeated for five minute periods.10. The method of claim 1, wherein, in step (d), 1-2 grams of carbonnanotubes (CNT) are added to the acetone-brass-copper mixture.
 11. Themethod of claim 2, wherein one or the one or more metals is copper oraluminum.
 12. The method of claim 1, wherein in step (e) the mixture ofbrass and copper is a 1:1 ratio of brass and copper.
 13. The method ofclaim 12, wherein the mixture of brass and copper comprises 9.1kilograms-13.6 kilograms (20 pounds-30 pounds) of each.
 14. The methodof claim 2, wherein 3.6 kilograms-9.1 kilograms (8 pounds-20 pounds) ofthe treated material is added to 41 kilograms-54.4 kilograms (90pounds-120 pounds) of the one or more metals.
 15. The method of claim14, wherein 5 kilograms-5.9 kilograms (11 pounds-13 pounds) of treatedmaterial is added to 41 kilograms-54.4 kilograms (90 pounds-120 pounds)of the one or more metals.
 16. The method of claim 1, wherein steps(b)-(d) are performed in any order to produce the solution.
 17. Themethod of claim 1, wherein any two or more of steps (a)-(d) are combinedto produce the solution.
 18. A method of treating a material comprising:(a) mixing solvent, brass granules, copper granules, and carbonnanotubes in the absence of silver, iron pyrite, and graphene; (b)adding the mixture of step (a) to an additional mixture of brass andcopper granules and mixing until all of the granules of the additionalmixture of brass and copper are uniformly saturated with the mixture ofstep (a); and (c) drying the mixture of step (b) to a powder to form atreated material.
 19. The method of claim 18, further including mixingthe treated material with one or more ferrous and/or nonferrous metal(s)in a high temperature crucible and heating until melted.
 20. The methodof claim 18, wherein step (a) includes mixing in a blender.